JP2007038490A - Molded body and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a molded body in which insulating layers of even thickness are formed in narrow clearances between a plurality of metal bodies, and provide its manufacturing method. <P>SOLUTION: The molded body 30 is formed by covering, so as to electrically insulate a plurality of sheet-like metal bodies 31, 32, the peripheries of each sheet-like metal body 31, 32 with an insulating polymer in such a state that the sheet-like metal bodies 31, 32 are separated by a predetermined space. Between each sheet-like metal body 31, 32 there is provided a spacer polymer part 34 composed of an insulating polymer having a melting point of T1, and the peripheries of the spacer polymer part 34 and each sheet-like metal body 31, 32 are covered with a molding part 33 composed of an insulating polymer having a melting point of T2 (<T1). <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a molded product in which each metal body is covered with an insulating polymer in a state where the metal bodies are spaced apart at a predetermined interval for the purpose of electrical insulation of a plurality of plate-like metal bodies, and a method for manufacturing the same. It is about.

  Conventionally, when insulating between metal bodies with a relatively high average electric field strength of several hundred V / mm or more with an insulating polymer, in order to ensure long-term reliability, the metal part is made of the insulating polymer. A technique of coating the body with a mold is generally used. As a mold coating technique, a technique in which an insulating polymer is injection-molded (or extruded) into a target shape while holding a portion of a metal body to be exposed is most often used.

  As shown in FIG. 10A, a general molded body 100 is obtained by molding and coating two plate-like metal bodies 101, 102 having a plurality of terminal portions 101a, 102a with a mold portion 103. The terminal portions 101 a and 102 a of the metal bodies 101 and 102 are exposed from the mold portion 103. As shown in FIG. 10B and FIG. 10C, the metal bodies 101 and 102 are insulated in a state of being separated at a predetermined interval.

  As shown in FIG. 11, the metal bodies 101 and 102 are set in the cavity 113 of the injection mold 110. The metal bodies 101 and 102 are fixed in the cavity 113 with the terminal portions 101 a and 102 a sandwiched between the upper mold 111 and the lower mold 112. Thereafter, the molten resin 116 is supplied into the cavity 113 from at least one injection head 115 provided in communication with the cavity 113. The mold part 103 is formed by cooling and solidifying the molten resin 116, and the molded article 100 shown in FIG. 10 is obtained.

  Examples of prior art document information related to the present invention include the following.

JP 2003-143868 A

  When the above-described insulating mold molded body is molded by injection molding, there are the following three main problems.

  (A) When the area of the resin having a high melt viscosity or the plate-like metal bodies 101 and 102 is increased, there is a limit in reducing the metal body interval (insulation thickness) 105.

  When the gap 105 between the metal bodies 101 and 102 is reduced with respect to the area of the metal bodies 101 and 102, the injection molding material (molten resin 116) becomes difficult to enter between the metal bodies 101 and 102. , 102 cannot form a defect-free insulating layer. In order to perform injection molding with high accuracy, nylon with a low viscosity at the time of melting is used for injection molding, but injection is performed with high accuracy and good moldability on metal bodies 101 and 102 having a side of about 200 mm. The moldable gap 105 is about 0.5 mm. When the gap 105 is smaller than that, the molten resin 116 does not reach the end portions (corners) of the cavity 113, and problems such as voids are likely to occur. Such insufficiency of the material leads to deterioration of the insulation characteristics between the metal bodies 101 and 102.

  (B) The uniformity of the gap 105 in the plate-like metal bodies 101 and 102 cannot be ensured.

  In the case where the plate-like metal bodies 101 and 102 having a relatively small thickness are insulated in a state of being spaced apart at a constant interval, and the outside of the metal bodies 101 and 102 is mold-coated with the mold portion 103, the metal bodies 101 and 102 are There are fewer parts to grip. As a result, the metal bodies 101 and 102 are deformed by the pressure of the injected molten resin 116, and the uniformity of the gap 105 is lost. If the uniformity of the gap 105 is lost, when a voltage is applied to the metal bodies 101 and 102, the electric field concentrates on a portion where the interval is narrow, which may cause defects in the insulating structure and impair long-term reliability. .

  (C) It is difficult to make the insulating material (insulating polymer) and the metal bodies 101 and 102 adhere to each other.

  The periphery of the plate-like metal bodies 101 and 102 or the gap 105 is a portion where an electric field is concentrated when a voltage is applied to the metal bodies 101 and 102. If peeling occurs at the interface between the metal bodies 101 and 102 and the insulating material due to repeated heating and cooling due to a temperature change in (or use environment), the insulating performance deteriorates, and the risk of dielectric breakdown increases. In addition, partial discharge occurs at the interface between the metal bodies 101 and 102 and the insulating material, which may significantly reduce the life. Therefore, it is necessary to firmly bond the insulating material and the metal bodies 101 and 102. However, when the insulating material contains an adhesive, the mold releasability deteriorates and the viscosity of the molten resin 116 increases. Formability will deteriorate. In addition, when an adhesive is applied to the metal bodies 101 and 102 in advance, there is a problem that the adhesive flows and moves due to the injection pressure of the insulating material, resulting in variations in the adhesive force.

  An object of the present invention created in view of the above circumstances is to provide a molded body capable of forming an insulating layer having a uniform thickness in a narrow gap between a plurality of metal bodies and a method for manufacturing the same. .

In order to achieve the above object, the molded body according to the present invention is provided around the respective plate-like metal bodies with the plate-like metal bodies spaced apart at a predetermined interval for the purpose of electrical insulation of the plurality of plate-like metal bodies. In a molded product in which is covered with an insulating polymer,
Between each plate-shaped metal body, there is a spacer polymer portion composed of an insulating polymer having a melting point of T1, and around the spacer polymer portion and each plate-shaped metal body, the melting point is T2 (<T1). It is covered with a mold part made of an insulating polymer.

  Here, it is preferable that the insulating polymer having a melting point of T1 is a polymer material having an aromatic polymer as a main component, and the insulating polymer having a melting point of T2 is a polymer material having a main component of polyolefin.

  An adhesive layer composed of an adhesive having a melting point T3 of T3 <T1 may be provided between each plate-like metal body and the spacer polymer portion and between each plate-like metal body and the mold portion. Further, a first adhesive layer and a second adhesive layer composed of an adhesive having a melting point T3 of T3 <T1 between each plate-like metal body and the spacer polymer part and between each plate-like metal body and the mold part. It is preferable that each layer is provided and each adhesive constituting the first adhesive layer and the second adhesive layer has high compatibility.

On the other hand, the method for producing a molded body according to the present invention is provided for the purpose of electrical insulation of a plurality of plate-like metal bodies around each plate-like metal body in a state where the plate-like metal bodies are spaced apart at a predetermined interval. In the method for producing a molded article covered with an insulating polymer,
A first sheet material made of an insulating polymer having a melting point of T1 is disposed between each plate-like metal body spaced at a predetermined interval,
A second sheet material made of an insulating polymer having a melting point of T2 (<T1) is placed on the outer side of each outermost sheet metal body,
The laminated body composed of each of the plate-shaped metal bodies, the first sheet material, and the second sheet material is subjected to a heat and pressure molding process at a temperature higher than T2 and lower than T1.
The second sheet material is melted while securing the interval between the respective plate metal bodies with the first sheet material, and the periphery of each plate metal body and the first sheet material is made of an insulating polymer having a melting point of T2. The mold part is covered.

In addition, the method for producing a molded body according to the present invention is provided around the respective plate-like metal bodies in a state where the plate-like metal bodies are separated at a predetermined interval for the purpose of electrical insulation of the plurality of plate-like metal bodies. In the method for producing a molded article covered with an insulating polymer,
A first sheet material made of an insulating polymer having a melting point of T1 is disposed between each plate-like metal body spaced at a predetermined interval,
Arrange the laminated body composed of each of the plate-like metal bodies and the first sheet material in the cavity of the injection mold,
An insulating polymer having a melting point of T2 (<T1) is injected into the cavity while being heated and melted at a temperature higher than T2 and lower than T1,
The space between the respective plate-like metal bodies is secured by the first sheet material, and the periphery of each plate-like metal body and the first sheet material is covered with a mold portion made of an insulating polymer having a melting point of T2. .

  Here, a plurality of first sheet materials may be disposed between the respective plate-like metal bodies.

  A first adhesive layer and a second adhesive layer made of an adhesive having a melting point T3 of T3 <T1 are integrally provided on the surface of the first sheet material and the metal body side surface of the second sheet material, respectively. After the pressure forming process, the first sheet material and the plate-like metal bodies may be bonded by the first adhesive layer, and the mold part and the plate-like metal bodies may be bonded by the second adhesive layer. Alternatively, the adhesives constituting the first adhesive layer and the second adhesive layer may be mixed to bond the first adhesive layer and the second adhesive layer.

  A first adhesive layer composed of an adhesive having a melting point T3 of T3 <T1 is integrally provided on the surface of the first sheet material, and each first sheet material is formed by the first adhesive layer after the heat and pressure forming process. Each plate-like metal body may be bonded.

  According to the present invention, a plurality of plate-like metal bodies can be mold-coated with an insulating polymer, and the plurality of plate-like metal bodies are insulated through an insulating layer having a thin and uniform thickness. Demonstrate the excellent effect of being able to.

  DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, a preferred embodiment of the invention will be described with reference to the accompanying drawings.

  FIG. 3 shows a structural diagram of a molded product according to a preferred embodiment of the present invention. 3A is a plan view, and FIG. 3B is a cross-sectional view taken along line 3B-3B of FIG.

  As shown in FIGS. 3 (a) and 3 (b), the molded body according to the present embodiment has a plurality of plate-like metal bodies (metal plates shown in FIG. 3 (b)). ) 31 and 32 are covered with a mold part 33.

  Between each of the metal plates 31 and 32, there is a spacer polymer portion 34 composed of an insulating polymer (described later) having a melting point (or softening point) T1 and an adhesive (described later) having a melting point T3 (T3 <T1). Provided. The periphery of the spacer polymer portion 34 and the metal plates 31 and 32 is covered with a mold portion 33 made of an insulating polymer (described later) having a melting point (or softening point) of T2 (<T1). Protruding portions (terminal portions) 31 a and 32 a protrude from the mold portion 33.

  The manufacturing method of the molded object which concerns on this Embodiment is demonstrated based on an accompanying drawing.

  First, as shown in FIG. 1, an adhesive having a relationship of melting point T3 T3 <T1 is applied to the surface (upper and lower surfaces in FIG. 1) of the first sheet material 11 made of an insulating polymer having a melting point T1. The configured first adhesive layers 12a and 12b are integrally provided to form the spacer polymer sheet 10. Here, the first adhesive layer may be provided only on one side of the first sheet material 11. The first adhesive layer is not necessarily provided.

  On the other hand, as shown in FIG. 2, the metal sheet side surface (the lower surface in FIG. 2) of the second sheet material 21 made of an insulating polymer having a melting point T2 (<T1) has a relationship that the melting point T3 is T3 <T1. The molded polymer sheet 20 is configured by integrally providing the second adhesive layer 22 composed of the adhesive in the above. Here, the second adhesive layer is not necessarily provided.

  Next, as shown in FIG. 4, the spacer polymer sheet 10 is sandwiched between the metal plates 31 and 32, and the second adhesive layer 22 side of the molded polymer sheets 20 and 20 is overlapped on the metal plates 31 and 32. By stacking, the stacked body 40 is formed. At this time, the metal plates 31 and 32 are laminated so that a part of the metal plates 31 and 32 protrudes from the laminated body 40. The tips of the metal plates 31 and 32 that protrude from the laminated body 40 become terminal portions 31a and 32a. A plurality of spacer polymer sheets 10 may be disposed between the metal plates 31 and 32. By adjusting the number of spacer polymer sheets 10 arranged, the gaps between the metal plates 31 and 32 in the molded body 30 described later can be freely adjusted. When the number of metal plates is three or more, the molded polymer sheets 20 are disposed only on the outer sides of the two outermost metal plates.

  The laminate 40 is disposed between the heating and pressing press hot plates 41 and 42 of the heating and pressing press molding machine. As shown in FIG. 5, the terminal portion 31 a is sandwiched between the upper die 43 and the lower die 44, and the terminal portion 31 a is seated on the step portion 44 a of the lower die 44. The terminal portion 32 a is sandwiched between the upper die 45 and the lower die 46, and the terminal portion 32 a is seated on the step portion 45 a of the upper die 45. At least one of the press hot plates 41 and 42 is connected to a cylinder (not shown) of a hydraulic piston or the like, and is movable in the directions of arrows A1 and A2, that is, the compression direction of the laminate 40.

  Next, the laminated body 40 is subjected to a heating and pressing process at a temperature higher than T2 and lower than T1. In addition, the pressure at the time of the heat and pressure forming process is particularly limited as long as it is a pressure that can sufficiently deform and flow when a molten polymer 63 (described later) formed by melting the second sheet material 21 flows. It is not a thing.

  As shown in FIG. 6, the first sheet material 11 of the spacer polymer sheet 10 is not melted during the heating and pressing process, and the shape is maintained. An interval (gap) corresponding to the thickness of one sheet material 11 is secured. Further, this gap is uniform over the surface direction of each metal plate 31, 32. Further, the second sheet material 21 of each mold polymer sheet 20 is melted by a heat and pressure forming process to become a molten polymer 63, and the molten polymer 63 is heated and pressed by hot plates 41 and 42, dies 43 and 44, And it flows so that the space 61 comprised with the metal mold | dies 45 and 46 may be filled up. In addition, each of the adhesives constituting the first adhesive layers 12a and 12b and the second adhesive layers 22 and 22 has a melting point T3 which is in the relationship of <T1 similarly to T2, and therefore a part thereof is melted by the heat and pressure molding process. And flows with the molten polymer 63. T3 may be either T3 ≦ T2 or T3 ≧ T2.

  As the molten polymer 63 that has spread into the space 61 is cooled and solidified, as shown in FIG. 7, the molded body in which the metal plates 31 and 32 and the first sheet material 11 are covered with the mold portion 33. 30 is obtained. The first sheet material 11 and the metal plates 31 and 32 are bonded via the remaining first adhesive layers 12a and 12b. Further, most of the mold side surface (the lower surface in FIG. 7) of the metal plate 31 and most of the mold portion 33 and the mold side surface (the upper surface in FIG. 7) of the metal plate 32 and the mold portion 33 remain in the second adhesion. Bonded through the layers 22, 22. A spacer polymer portion 34 is configured by the first sheet material 11 and the remaining first adhesive layers 12a and 12b. When the first adhesive layer is not provided on the first sheet material 11, the first sheet material 11 itself becomes the spacer polymer portion 34.

  Here, the larger the difference between the melting points of the insulating polymer having the melting point T1 constituting the first adhesive layers 12a and 12b and the insulating polymer having the melting point T2 constituting the second adhesive layer 22, the larger the molding body 30 has. Manufacture is easy and stable.

  As the insulating polymer having a melting point of T1, a polymer material mainly composed of an aromatic polymer is suitable. Further, as the insulating polymer having a melting point of T2, polymer materials mainly composed of polyolefin and various elastomers are suitable. That is, as the insulating polymer having a melting point T1, it is preferable to use a first polymer having a first adhesion mechanism that can provide strong adhesion to an aromatic polymer material. On the other hand, as the insulating polymer having a melting point of T2, it is preferable to use a second polymer having a second adhesion mechanism capable of obtaining strong adhesion to a metal material. It is more preferable that each polymer has high compatibility. In this case, when the second adhesive layer 22 is provided on the spacer polymer sheet 10 side of each of the metal plates 31 and 32, the first adhesive layers 12a and 12b and the second adhesive layers 22 and 22 are adjacent to each other. At this time, when the first polymer and the second polymer have high compatibility, the first adhesive layers 12a and 12b and the second adhesive layers 22 and 22 are firmly bonded to each other. The plates 31 and 32 and the first sheet material 11 can be bonded more firmly.

The first bonding mechanism uses a styrene-based elastomer (polymer) having a styrene block highly compatible with an aromatic polymer as an adhesive. When the adhesive and the aromatic polymer material are heated and pressurized, The styrene block portion and the aromatic polymer are compatible with each other, and the adhesive and the aromatic polymer material are firmly bonded. Here, the aromatic polymer means a polymer having an aromatic ring in the main chain, for example,
Polyphenylene ether (PPE),
Polyetherimide (PEI),
Polycarbonate (PC),
Polyethersulfone,
Polyimide,
Polyphenylene sulfide,
Polysulfone,
Polyetheretherketone,
However, it is not limited to these. On the other hand, as a styrene-based elastomer having a styrene block, for example,
Triblock copolymers such as styrene-ethylenebutylene-styrene copolymer (SEBS), styrene-ethylenepropylene-styrene copolymer (SEPS), styrene-butylene-styrene copolymer (SBS),
Diblock copolymers such as hydrogenated styrene-butadiene rubber,
Etc.

The second adhesive mechanism uses an acid-modified or epoxy-modified polymer as an adhesive, so that the acid group site or epoxy group site of the polymer is hydrogen-bonded to water molecules or oxides on the metal surface, and the adhesive And the metal material are firmly bonded. Typical examples of acid modification of polymers include maleic acid modification. Examples of polymers obtained by acid modification include, for example,
Elastomers such as SBS, SEBS, polyisobutylene (PIB),
Polymers including olefins such as polyethylene (PE) and polypropylene,
Is mentioned. On the other hand, as a polymer having an epoxy group, for example,
A glycidylated copolymer of polyethylene and polystyrene,
A glycidylated copolymer of ethylene-glycidyl methacrylate copolymer (EGMA) and polystyrene (PS),
Etc.

  According to the method of manufacturing a molded body according to the present embodiment, a thin insulating layer is obtained by performing mold coating of the mold portion 33 in a state where the spacer polymer sheet 10 is disposed between the metal plates 31 and 32. The spacer polymer portion 34 (see FIG. 3B) can be formed uniformly. That is, the metal plates 31 and 32 can be mold-coated with the mold part 33, and the metal plates 31 and 32 can be insulated from each other through a thin and uniform insulating layer. The formation of the spacer polymer portion 34 is not affected by the size of the area of the metal plates 31 and 32 and the size of the separation distance of the metal plates 31 and 32. Further, the thickness of the spacer polymer portion 34, that is, the gap between the metal plates 31 and 32 is uniform over the metal plate surface direction.

  Further, the mold part 33 and the spacer polymer part 34 of the molded body according to the present embodiment are not formed by injection molding as in the conventional method of manufacturing a molded body shown in FIG. It can be formed by pressure forming. That is, the mold part 33 and the spacer polymer part 34 are manufactured by using a simple frame composed of the heating and pressing press hot plates 41 and 42, the molds 43 and 44, and the molds 45 and 46 shown in FIG. It is not necessary to use an expensive mold for injection molding. Therefore, the molded body 30 can be manufactured at low cost.

  In addition, the shape and thickness of the second sheet material 21 used for manufacturing the molded body 30 according to the present embodiment is 10 to more than the minimum required volume in consideration of the final volume of the mold part 33. The volume is adjusted to increase by 40%. In other words, the shape and thickness of the second sheet material 21 are adjusted so that the overflow amount of the molten polymer 63 is 10 to 40% of the actual volume amount of the mold part 33. By sufficiently taking the overflow amount of the molten polymer 63, the shape reproducibility of the mold part 33 is enhanced.

  Further, when the metal plates 31 and 32 are coated with the mold part 33, the adhesion strength between the metal plates 31 and 32 and the mold part 33, that is, the peel strength between the metal plates 31 and 32 and the mold part 33 is determined. The size is the main factor that determines the insulation performance of the molded body 30. Therefore, in the molded body 30 according to the present embodiment, the metal plates 31 and 32 and the mold part 33 are bonded via an adhesive. Specifically, the surfaces of the first sheet material 11 and the second sheet material 21, the surfaces of the metal plates 31, 32, or the surfaces of the first sheet material 11, the second sheet material 21, and the metal plates 31, 32. In addition, an adhesive layer is formed in advance. As a result, the metal plates 31 and 32 and the mold part 33 can be adhered uniformly and firmly, and the insulation performance of the molded body 30 can be maintained well over a long period.

  Further, the adhesive strength between the insulating polymer having a melting point of T2 and the metal plates 31 and 32 can be freely adjusted by adjusting the amount of acid modification (or epoxy modification) of the acid modified (or epoxy modified) polymer. it can. Further, the adhesive strength between the insulating polymer having the melting point T1 and the first sheet material 11 can be freely adjusted by adjusting the amount of styrene in the styrene block portion of the styrene elastomer.

  The molded body 30 according to the present embodiment is suitable for, for example, a mold type power supply bus plate.

  Further, in the present embodiment, as shown in FIG. 6, the mold part is formed by using a frame constituted by heating and pressing press hot plates 41 and 42, molds 43 and 44, and molds 45 and 46. Although the case where 33 was formed was demonstrated, it is not limited to this. For example, the mold part 33 may be formed using a lower metal frame 81 and an upper metal frame (not shown) shown in FIGS. 8A and 8B as the frame. The lower metal frame 81 corresponds to an integrated heating and pressing press hot plate 42 and lower metal molds 44 and 46, and in the space 82 in the lower metal frame 81, the mold polymer sheet 20, the metal plate 31, and Spacer polymer sheet 10 is accommodated. On the other hand, the upper metal frame corresponds to an integrated heating / pressing press hot plate 41 and upper molds 43 and 45, and the metal plate 32 and the molded polymer sheet 20 are accommodated in the space in the upper metal frame. The

  Next, another embodiment of the present invention will be described with reference to the accompanying drawings.

  The method for manufacturing a molded body according to the previous embodiment is to form a mold part using a heat and pressure molding process. On the other hand, the method for producing a molded body according to the present embodiment forms the mold part using injection molding.

  Specifically, first, the melting point T3 has a relationship of T3 <T1 on the surface (upper and lower surfaces in FIG. 1) of the first sheet material 11 made of the insulating polymer having the melting point T1 shown in FIG. The spacer polymer sheet 10 is configured by integrally providing first adhesive layers 12a and 12b made of an adhesive.

  Next, by sandwiching and laminating the spacer polymer sheet 10 between the metal plates 31 and 32, a laminate 90 is formed as shown in FIG. At this time, the metal plates 31 and 32 are laminated so that a part of the metal plates 31 and 32 protrudes from the laminated body 90. The tips of the metal plates 31 and 32 that protrude from the laminated body 90 become terminal portions 31a and 32a. A plurality of spacer polymer sheets 10 may be disposed between the metal plates 31 and 32. By adjusting the number of spacer polymer sheets 10 arranged, the gaps between the metal plates 31 and 32 described later can be freely adjusted.

  The laminated body 90 is once disposed between the press hot plates of the press molding machine, and then subjected to heat treatment. Thus, the first adhesive layers 12a and 12b are melted, and the metal plates 31 and 32 and the first sheet material 11 are bonded via the first adhesive layers 12a and 12b. Thereafter, the bonded laminate 90 is set in the cavity 93 of the injection mold 90. The metal plates 31 and 32 are fixed in the cavity 93 with the terminal portions 31 a and 32 a sandwiched between the upper mold 92 and the lower mold 92. Thereafter, molten polymer 96 is supplied into the cavity 93 from at least one injection head 95 provided in communication with the cavity 93. The molten polymer 96 is obtained by heating and melting an insulating polymer having a melting point T2 (<T1) at a temperature higher than T2 and lower than T1.

  At the time of this injection molding, the first sheet material 11 of the spacer polymer sheet 10 is not melted and the shape is maintained. Therefore, the gap between the metal plates 31 and 32 is approximately equal to the thickness of the first sheet material 11. (Gap) is secured. Further, this gap is uniform over the surface direction of each metal plate 31, 32. Further, the molten polymer 96 flows so as to fill the gap of the cavity 93. Further, since the adhesive constituting the first adhesive layers 12 a and 12 b has a melting point T 3 of T 3 <T 1, a part thereof is melted by the temperature at the time of injection molding and flows together with the molten polymer 96.

  The molten polymer 96 that has spread into the cavity 93 is cooled and solidified, so that the molded body 30 (see FIG. 3) in which the metal plates 31 and 32 and the first sheet material 11 are covered with the mold portion 33 is formed. can get. The first sheet material 11 and the metal plates 31 and 32 are bonded via the remaining first adhesive layers 12a and 12b.

  Unlike the method for producing a molded body according to the previous embodiment, the method for producing a molded body according to the present embodiment forms a mold part using injection molding, and therefore requires an expensive injection mold. And However, the method for producing a molded body according to the present embodiment performs mold coating on the laminate 90 having at least a three-layer structure, and does not require the mold polymer sheet 20 shown in FIG. Therefore, as compared with the method for manufacturing a molded body according to the previous embodiment in which mold coating is performed on the laminate 40 having at least a five-layer structure, the steps required to form the laminate can be simplified.

  As described above, the present invention is not limited to the above-described embodiment, and it goes without saying that various other things are assumed.

  Next, although this invention is demonstrated based on an Example, this invention is not limited to this Example.

  Prepare two copper plates (200mm x 280mm, thickness t is 1mm) as a plate-shaped metal body, and as shown in Fig. 3 (b), the lap width L is 210mm and the distance between the copper plates is 0.4mm. The mold area (240 mm × 250 mm) including the wrap area was mold-coated.

Example 1
As shown in FIG. 1, a PPE sheet (manufactured by Asahi Kasei Co., Ltd., Zylon 540Z, thickness t is 0.4 mm) prepared by applying a thermosetting adhesive layer on both sides is prepared. It was cut into a size (220mm x 230mm) larger by 10mm in length and breadth. Also, as shown in FIG. 2, a flame-retardant PE resin sheet (manufactured by Ube Industries, Z555, thickness t is 2.5 m) having a hot-melt adhesive layer formed on one side is prepared. The flame retardant PE resin sheet was cut and formed so that the volume of the flame retardant PE resin sheet was larger than the value obtained by subtracting the volume of the copper plate and the PPE sheet from the volume of the molded body of 240 mm × 250 mm × 5 mm (220 mm × 230mm x 2.5mm). Further, a lower die 81 shown in FIG. 8 and a frame body constituted by the lower die frame 81 and a pair of upper die frames were prepared.

  In this frame, a laminated body in which a flame retardant PE resin sheet, a copper plate, a PPE sheet, a copper plate, and a flame retardant PE resin sheet were stacked in this order was disposed. The laminate was sandwiched between the heating and pressing press hot plates together with the frame and set in a heating and pressing press molding machine heated to 130 ° C. After sufficient preheating, a pressure of 0.5 MPa was applied to perform heat and pressure molding treatment to produce a molded body (sample 1) having the structure shown in FIG.

  As a result, in Sample 1, a very thin uniform insulating layer (spacer polymer portion) could be formed between copper plates having a side of about 200 mm and a separation distance of 0.4 mm. As a result of measuring the partial discharge occurrence extinction (10pC) voltage of this sample 1, a value of 8 kV or more was obtained. Between the copper plates of this molded body and around the copper plates, voids having a size that adversely affects electrical insulation were obtained. There was no outbreak.

  In addition, after repeating the heat cycle of −25 ° C. to 105 ° C. 100 times for this sample 1, the partial discharge start extinction voltage was measured again. As a result, the same value of 8 kV or more as before the heat cycle was applied was obtained It was. That is, even when a heat cycle was applied, no peeling or void occurred at the interface between the copper plate and the PPE sheet, and it was confirmed that the copper plate and the PPE sheet were firmly bonded.

(Example 2)
The same PPE sheet as in Example 1 was produced. Moreover, the injection mold 90 shown in FIG. 9 was prepared as a frame.

  The laminated body which laminated | stacked the copper plate, the PPE sheet | seat, and the copper plate in order was pinched | interposed between the hot press hot plates of a press molding machine, and it heated at 130 degreeC. By this heat treatment, the adhesive layer of the PPE sheet was melted, and the copper plate and the PPE sheet were bonded via the adhesive layer. After this laminated body is placed in the cavity 93 of the injection mold 90, the molten flame-retardant PE resin is injected into the cavity 93 for injection molding, and a molded body having the structure shown in FIG. ) Was produced.

  As a result, in Sample 2, a very thin uniform insulating layer (spacer polymer portion) could be formed between copper plates having a side of about 200 mm and a separation distance of 0.4 mm. As a result of measuring the partial discharge occurrence extinction (10pC) voltage of Sample 2, a value of 8 kV or more was obtained, and voids having a size that adversely affects electrical insulation between and around the copper plate of this molded product There was no outbreak.

  In addition, after repeating the heat cycle of −25 ° C. to 105 ° C. 100 times for this sample 2, the partial discharge start extinction voltage was measured again. As a result, the same value of 8 kV or more as before the heat cycle was applied was obtained. It was. That is, even when a heat cycle was applied, no peeling or void occurred at the interface between the copper plate and the PPE sheet, and it was confirmed that the copper plate and the PPE sheet were firmly bonded.

(Comparative Example 1)
An injection mold 110 shown in FIG. 11 was prepared as a frame.

  After the copper plate is placed in the cavity 113 of the injection mold 110, molten polyphenyl ether (PPE, manufactured by Asahi Kasei Co., Ltd., Zylon 540Z) is injected into the cavity 113 to perform injection molding, and a molded product ( Sample 3) was prepared.

  As a result of measuring the partial discharge occurrence extinction (10 pC) voltage of Sample 3, it was a very low value of 1 kV or less. As a result of cutting this molded body and observing the cross section, generation of large voids that adversely affect the electrical insulation between the copper plates was confirmed.

It is sectional drawing of the spacer polymer sheet used for the manufacturing method of the molded object which concerns on preferable one Embodiment of this invention. It is sectional drawing of the mold polymer sheet used for the manufacturing method of the molded object which concerns on preferable one Embodiment of this invention. 1 is a structural diagram of a molded product according to a preferred embodiment of the present invention. 3A is a plan view, and FIG. 3B is a cross-sectional view taken along line 3B-3B of FIG. It is a figure which shows the lamination | stacking state of the laminated body for manufacturing the molded object which concerns on preferable one Embodiment of this invention. It is a figure which shows the state which has arrange | positioned the laminated body of FIG. 4 between the heating-pressing press hotplates of a heating-pressing press. It is a figure which shows the state which performed the heat press molding process to the laminated body of FIG. It is sectional drawing which shows the 1st modification of FIG. It is a figure which shows the modification of the frame used for the manufacturing method of the molded object which concerns on suitable one embodiment of this invention. 8A is a plan view, and FIG. 8B is a view taken in the direction of the arrow 8B in FIG. 8A. It is a figure for demonstrating the manufacturing method of the molded object which concerns on other preferable one Embodiment of this invention. It is a structure diagram of a general bus plate. 10 (a) is a plan view, FIG. 10 (b) is a view taken in the direction of arrow 10B in FIG. 10 (a), and FIG. 10 (c) is a sectional view taken along line 10C-10C in FIG. 10 (a). It is a figure for demonstrating the manufacturing method of the conventional molded object.

Explanation of symbols

30 Molded body 31, 32 Metal plate (plate-shaped metal body)
33 Mold part 34 Spacer polymer part

Claims (10)

For the purpose of electrical insulation of a plurality of plate-like metal bodies, etc., in a molded product formed by covering each plate-like metal body with an insulating polymer in a state where the plate-like metal bodies are separated at a predetermined interval,
Between each of the above plate-like metal bodies has a spacer polymer portion composed of an insulating polymer having a melting point of T1,
A molded product comprising the spacer polymer portion and each of the plate-like metal bodies covered with a mold portion made of an insulating polymer having a melting point of T2 (<T1).   2. The molded article according to claim 1, wherein the insulating polymer having a melting point T1 is a polymer material mainly composed of an aromatic polymer, and the insulating polymer having a melting point T2 is a polymer material mainly composed of a polyolefin.   An adhesive layer made of an adhesive having a melting point T3 of T3 <T1 is provided between each of the plate-like metal bodies and the spacer polymer portion and between each of the plate-like metal bodies and the mold portion. The molded article according to claim 1 or 2.   A first adhesive layer and a first adhesive layer formed of an adhesive having a melting point T3 of T3 <T1 between each of the plate-like metal bodies and the spacer polymer part and between each of the plate-like metal bodies and the mold part. The molded article according to claim 3, wherein two adhesive layers are provided, and each adhesive constituting the first adhesive layer and the second adhesive layer has high compatibility. In a method of manufacturing a molded body in which a plurality of plate-like metal bodies are covered with an insulating polymer in a state where the plate-like metal bodies are separated at a predetermined interval for the purpose of electrical insulation of a plurality of plate-like metal bodies, etc. ,
A first sheet material made of an insulating polymer having a melting point of T1 is disposed between the plate-like metal bodies spaced apart by a predetermined distance.
A second sheet material made of an insulating polymer having a melting point of T2 (<T1) is placed on the outer side of each outermost sheet metal body,
The laminated body composed of each of the plate-shaped metal bodies, the first sheet material, and the second sheet material is subjected to a heat and pressure molding process at a temperature higher than T2 and lower than T1.
The second sheet material is melted while securing the interval between the plate metal bodies with the first sheet material, and the insulating polymer having a melting point of T2 is placed around each plate metal body and the first sheet material. A method for producing a molded product, characterized in that the molded product is covered with a mold part comprising: In a method of manufacturing a molded body in which a plurality of plate-like metal bodies are covered with an insulating polymer in a state where the plate-like metal bodies are separated at a predetermined interval for the purpose of electrical insulation of a plurality of plate-like metal bodies, etc. ,
A first sheet material made of an insulating polymer having a melting point of T1 is disposed between the plate-like metal bodies spaced apart by a predetermined distance.
Arrange the laminated body composed of each of the plate-like metal bodies and the first sheet material in the cavity of the injection mold,
An insulating polymer having a melting point of T2 (<T1) is injected into the cavity while being heated and melted at a temperature higher than T2 and lower than T1,
Cover each plate-like metal body and the first sheet material with a mold part made of an insulating polymer having a melting point of T2, while securing the interval between the plate-like metal bodies with the first sheet material. A method for producing a molded article characterized by the above.   The method for producing a molded body according to claim 5 or 6, wherein a plurality of the first sheet materials are arranged between the plate-like metal bodies.   A first adhesive layer and a second adhesive layer each made of an adhesive having a melting point T3 of T3 <T1 are integrally provided on the surface of the first sheet material and the metal body side surface of the second sheet material, The first sheet material and the plate metal bodies are bonded to each other by the first adhesive layer after the heat and pressure forming treatment, and the mold part and the plate metal bodies are bonded to each other by the second adhesive layer. 8. A method for producing a molded article according to 7.   The method for producing a molded body according to claim 8, wherein the adhesives constituting the first adhesive layer and the second adhesive layer are mixed to bond the first adhesive layer and the second adhesive layer. A first adhesive layer composed of an adhesive having a melting point T3 of T3 <T1 is integrally provided on the surface of the first sheet material, and after the heat and pressure molding process, each first adhesive layer is formed by the first adhesive layer. The method for producing a molded body according to claim 6 or 7, wherein the sheet material and each of the plate metal bodies are bonded.

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